U.S. patent number 8,165,624 [Application Number 12/927,384] was granted by the patent office on 2012-04-24 for case for an electronic device with a wireless communication function and method for forming the same.
This patent grant is currently assigned to Advanced International Multitech Co., Ltd.. Invention is credited to Chieh-Fu Tseng.
United States Patent |
8,165,624 |
Tseng |
April 24, 2012 |
Case for an electronic device with a wireless communication
function and method for forming the same
Abstract
A method for forming a case of an electronic device with a
wireless communication function includes: (a) providing a pair of
outer prepreg layers, each containing a fiber that permits
permeation of an electromagnetic wave; (b) providing a plurality of
inner prepreg layers, each of which includes: a first prepreg sheet
that contains a first fiber, which permits permeation of an
electromagnetic wave; and a second prepreg sheet containing a
second fiber that prevents permeation of an electromagnetic wave
and that has a strength higher than that of the first fiber; (c)
stacking and pressing the inner prepreg layers to obtain an inner
laminate; (d) disposing the inner laminate between the outer
prepreg layers; and (e) forming the outer prepreg layers and the
inner laminate in a mold. A case for an electronic device with a
wireless communication function is also disclosed.
Inventors: |
Tseng; Chieh-Fu (Kaohsiung,
TW) |
Assignee: |
Advanced International Multitech
Co., Ltd. (Kaohsiung, TW)
|
Family
ID: |
44011651 |
Appl.
No.: |
12/927,384 |
Filed: |
November 12, 2010 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20110117872 A1 |
May 19, 2011 |
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Foreign Application Priority Data
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Nov 13, 2009 [TW] |
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98138635 A |
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Current U.S.
Class: |
455/550.1;
379/433.01; 343/702; 455/347; 455/90.3 |
Current CPC
Class: |
B29C
43/203 (20130101); B29C 43/3642 (20130101); B29C
70/882 (20130101); B29C 70/46 (20130101); B29L
2031/3481 (20130101); B29C 2043/3649 (20130101); B29K
2105/0854 (20130101) |
Current International
Class: |
H04M
1/00 (20060101) |
Field of
Search: |
;455/90.3,347,550.1,575.1,575.8 ;379/428.01,433.01,437
;343/702,718 |
References Cited
[Referenced By]
U.S. Patent Documents
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6489930 |
December 2002 |
Teshirogi et al. |
6518932 |
February 2003 |
Matsui et al. |
6832081 |
December 2004 |
Hiramatsu et al. |
6947764 |
September 2005 |
Carillo et al. |
7728780 |
June 2010 |
Ishida |
|
Primary Examiner: Le; Nhan
Attorney, Agent or Firm: DLA Piper LLP (US)
Claims
What is claimed is:
1. A method for forming a case of an electronic device with a
wireless communication function, the case having an antenna region
and a non-antenna region, the method comprising: (a) providing a
pair of outer prepreg layers adapted to form the antenna region and
the non-antenna region, each of the outer prepreg layers containing
a fiber that permits permeation of an electromagnetic wave; (b)
providing a plurality of inner prepreg layers, each of which
includes: a first prepreg sheet that is adapted to form the antenna
region and that contains a first fiber, which permits permeation of
an electromagnetic wave; and a second prepreg sheet that is
connected to the first prepreg sheet and that is adapted to form
the non-antenna region, the second prepreg sheet containing a
second fiber that prevents permeation of an electromagnetic wave
and that has a strength higher than that of the first fiber; (c)
stacking and pressing the inner prepreg layers to obtain an inner
laminate; (d) disposing the inner laminate between the outer
prepreg layers; and (e) forming the outer prepreg layers and the
inner laminate in a mold.
2. The method of claim 1, wherein the fiber contained in the outer
prepreg layers and the first fiber are selected from the group
consisting of glass fiber, basalt fiber, and Kevlar fiber.
3. The method of claim 1, wherein the second fiber includes carbon
fiber.
4. The method of claim 1, wherein, in step (b), the first prepreg
sheet is connected to the second prepreg sheet by overlapping the
first prepreg sheet with the second prepreg sheet in each of the
inner prepreg layers, and wherein, when the inner prepreg layers
are stacked in step (c), locations of the overlapping portions of
the first and second prepreg sheets of the inner prepreg layers are
staggered relative to each other.
5. The method of claim 4, wherein the locations of the overlapping
portions of the first and second prepreg sheets of the inner
prepreg layers are staggered relative to each other by a distance
ranging from 3 mm to 30 mm.
6. A case for an electronic device with a wireless communication
function, the case having an antenna region and a non-antenna
region and comprising: a pair of outer prepreg layers adapted to
form said antenna region and said non-antenna region, each of said
outer prepreg layers containing a fiber that permits permeation of
an electromagnetic wave; and an inner laminate disposed between
said outer prepreg layers and including a plurality of inner
prepreg layers, each of said inner prepreg layers including: a
first prepreg sheet that is adapted to form said antenna region and
that contains a first fiber, which permits permeation of an
electromagnetic wave; and a second prepreg sheet that is adapted to
form said non-antenna region, said second prepreg sheet containing
a second fiber that prevents permeation of an electromagnetic wave
and that has a strength higher than that of said first fiber.
7. The case of claim 6, wherein said fiber contained in said outer
prepreg layers and said first fiber are selected from the group
consisting of glass fiber, basalt fiber, and Kevlar fiber.
8. The case of claim 7, wherein said second fiber includes carbon
fiber.
9. The case of claim 6, wherein said first prepreg sheet is
overlapped with said second prepreg sheet in each of said inner
prepreg layers, and wherein locations of the overlapping portions
of said first and second prepreg sheets of said inner prepreg
layers are staggered relative to each other.
10. The case of claim 9, wherein the locations of said overlapping
portions of said first and second prepreg sheets of said inner
prepreg layers are staggered relative to each other by a distance
ranging from 3 mm to 30 mm.
11. The case of claim 6, wherein an area of each of said first
prepreg sheets is less than 30% of an area of a corresponding one
of said inner prepreg layers.
12. The case of claim 6, wherein a total weight of said outer
prepreg layers is less than 40% of a weight of said case.
Description
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority of Taiwanese application no.
098138635, filed on Nov. 13, 2009.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a case for an electronic device and a
method for forming the case.
2. Description of the Related Art
Taiwanese patent publication no. 529326 discloses a process for
producing cases of notebook computers, mobile phones or personal
digital assistants (PDAs). The process is intended to produce
integrally formed cases and includes stacking a plurality of
prepreg layers, followed by forming the prepreg layers into one
piece using heat pressing. Each of the prepreg layers is made from
carbon fiber fabric, glass fiber fabric, or Kevlar fiber
fabric.
Although the carbon fiber fabric has properties of lightweight,
high-strength and good electromagnetic wave shielding, it also
blocks the permeation of radio waves. However, with the development
of radio communication and wireless fidelity (Wi-Fi) communication
in notebook computers, wireless data transmission would be limited
if a case of a notebook computer is made entirely using carbon
fiber. On the other hand, if the case of the notebook computer is
made entirely using glass fiber, although the wireless transmission
would not be blocked, the case would have a relatively low strength
since the glass fiber has a lower rigidity compared to the carbon
fiber.
Referring to FIG. 1, in order to solve the above problem, the
conventional case 1 of the notebook computer generally includes two
portions. One portion is a non-antenna region 11 and another
portion includes three antenna regions 12. The non-antenna region
11 is made of carbon fiber and each of the antenna regions 12 is
made of a plastic material or glass fiber. The non-antenna region
11 is made by heat pressing a plurality of carbon fiber prepreg
layers, followed by forming three notches 12'. The antenna regions
12 are respectively secured to the non-antenna region 11 using an
adhesive or screws and cover the notches 12'. However, the
non-antenna region 11 and the antenna regions 12 are separately
made using different molds. Accordingly, the process for forming
the conventional case 1 of the notebook computer is conducted at a
relatively high cost. Furthermore, the conventional case 1 has
bonding lines that are formed among the non-antenna region 11 and
the antenna regions 12 and that are detrimental to the appearance
of the case 1.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a case
for an electronic device with a wireless communication function and
a method for forming the case that can overcome the aforesaid
drawbacks associated with the prior art.
According to one aspect of this invention, there is provided a
method for forming a case of an electronic device, the case having
an antenna region and a non-antenna region with a wireless
communication function, the method comprising:
(a) providing a pair of outer prepreg layers adapted to form the
antenna region and the non-antenna region, each of the outer
prepreg layers containing a fiber that permits permeation of an
electromagnetic wave;
(b) providing a plurality of inner prepreg layers, each of which
includes: a first prepreg sheet that is adapted to form the antenna
region and that contains a first fiber, which permits permeation of
an electromagnetic wave; and a second prepreg sheet that is
connected to the first prepreg sheet and that is adapted to form
the non-antenna region, the second prepreg sheet containing a
second fiber that prevents permeation of an electromagnetic wave
and that has a strength higher than that of the first fiber;
(c) stacking and pressing the inner prepreg layers to obtain an
inner laminate;
(d) disposing the inner laminate between the outer prepreg layers;
and
(e) forming the outer prepreg layers and the inner laminate in a
mold.
According to another aspect of this invention, there is provided a
case for an electronic device with a wireless communication
function, the case having an antenna region and a non-antenna
region and comprising:
a pair of outer prepreg layers adapted to form the antenna region
and the non-antenna region, each of the outer prepreg layers
containing a fiber that permits permeation of an electromagnetic
wave; and
an inner laminate disposed between the outer prepreg layers and
including a plurality of inner prepreg layers, each of the inner
prepreg layers including: a first prepreg sheet that is adapted to
form the antenna region and that contains a first fiber, which
permits permeation of an electromagnetic wave; and a second prepreg
sheet that is adapted to form the non-antenna region, the second
prepreg sheet containing a second fiber that prevents permeation of
an electromagnetic wave and that has a strength higher than that of
the first fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will become
apparent in the following detailed description of the preferred
embodiment of the invention, with reference to the accompanying
drawings, in which:
FIG. 1 is a perspective view illustrating a conventional notebook
computer case;
FIG. 2 is a flow chart illustrating consecutive steps of the
preferred embodiment of the method for forming a notebook computer
case according to the present invention;
FIG. 3 is a schematic view illustrating a pair of outer prepreg
layers formed according to the preferred embodiment of FIG. 2;
FIG. 4 is a schematic view illustrating four inner prepreg layers
of an inner laminate formed according to the preferred embodiment
of FIG. 2;
FIG. 5 is a cross-sectional view taken from line V-V shown in FIG.
4 to illustrate a first prepreg sheet overlapped with a second
prepreg sheet in each of the inner prepreg layers;
FIG. 6 is a schematic view illustrating how overlapping portions of
the first and second prepreg sheets of the inner prepreg layers
shown in FIG. 5 are staggered relative to each other;
FIG. 7 is a schematic view illustrating how the inner laminate is
disposed between the outer prepreg layers;
FIG. 8 is a schematic view illustrating how the outer prepreg
layers and the inner laminate are formed in a mold; and
FIG. 9 is a schematic view illustrating the case obtained after
curing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 2 and 9, the preferred embodiment of a method
for forming a case 8 of an electronic device with a wireless
communication function according to the present invention is shown.
The case 8 has an antenna region 81 and a non-antenna region 82.
Preferably, the case 8 is a notebook computer case.
In step 21, a pair of outer prepreg layers 31 are cut from a
prepreg fabric so that each of the outer prepreg layers 31 has a
size sufficient to form the case 8 (see FIG. 3). The outer prepreg
layers 31 are adapted to form the antenna region 81 and the
non-antenna region 82. Each of the outer prepreg layers 31 contains
a fiber that permits permeation of an electromagnetic wave (a radio
wave). In the preferred embodiment, the fiber contained in the
outer prepreg layers 31 may be selected from glass fiber, basalt
fiber and Kevlar fiber based on the actual requirement of the case
8 of the electronic device.
In step 22, a plurality of inner prepreg layers 41 are provided
(see FIG. 4). Each of the inner prepreg layers 41 includes a first
prepreg sheet 411 and a second prepreg sheet 412. The first prepreg
sheet 411 of each of the inner layers 41 may be cut from a first
fabric layer, is adapted to form the antenna region 81, and
contains a first fiber. The second prepreg sheet 412 of each of the
inner prepreg layers 41 may be cut from a second fabric layer, is
adapted to form the non-antenna region 82, and contains a second
fiber. After the first and second prepreg sheets 411, 412 of each
of the inner prepreg layers 41 are respectively cut from the first
and second fabric layers, the first prepreg sheet 411 is seamlessly
connected to the second prepreg sheet 412 so that each of the inner
prepreg layers 41 has a size corresponding to the size of each of
the outer prepreg layers 31.
In this preferred embodiment, four pieces of the inner prepreg
layers 41 are provided. However, the number of the inner prepreg
layers 41 may range from 2 to 12 based on the actual requirement of
the case 8 of the electronic device.
In the preferred embodiment, the first fiber can permit permeation
of an electromagnetic wave (a radio wave) and may be glass fiber,
basalt fiber, or Kevlar fiber. The second fiber prevents permeation
of an electromagnetic wave (a radio wave), has a strength higher
than that of the first fiber so as to enhance the strength of the
case 8, and may be carbon fiber.
In the preferred embodiment, the seamless connection of the first
and second prepreg sheets 411, 412 is accomplished by overlapping
the first prepreg sheet 411 with the second prepreg sheet 412 in
each of the inner prepreg layer 41 (see FIG. 5). The overlapping
portions 413 of the first and second prepreg sheets 411, 412 become
seamless when they are formed under pressure and heat in subsequent
steps.
Referring to FIGS. 4 and 6, the widths of the first prepreg sheets
411 of the four pieces of the inner prepreg layers 41 are different
from each other and are denoted by L1, L2, L3 and L4, respectively.
The width differences among the first prepreg sheets 411 (i.e.,
|L1-L2|, |L1-L3|, or |L1-L4|) range from 3 mm to 30 mm.
Furthermore, an area of each of the first prepreg sheets 411 is
less than 30% of an area of a corresponding one of the inner
prepreg layers 41.
In step 23, the inner prepreg layers 41 are stacked by aligning
corresponding corners of the inner prepreg layers 41, and are
roller-pressed to obtain an inner laminate 4 (see FIG. 6). Because
the widths of the first prepreg sheets 411 in the four inner
prepreg layers 41 are different from each other as mentioned
hereinabove, locations (L5) of the overlapping portions 413 of the
first and second prepreg sheets 411, 412 of the inner prepreg
layers 41 are staggered relative to each other by a distance
ranging from 3 mm to 30 mm, as shown in FIGS. 5 and 6. In FIG. 6, a
gap shown between the first and second prepreg sheets 411, 412 in
each of the inner prepreg layers 41 is used to explain the
locations (L5) of the overlapping portions 413 of the first and
second prepreg sheets 411, 412 in an exploded way. It is noted that
no such gap is present in the case product obtained according to
the method of the present invention.
In step 24, the inner laminate 4 is disposed between the outer
prepreg layers 31, and the corners of the inner laminate 4 and the
outer prepreg layers 31 are aligned.
In step 25, the inner laminate 4 and the outer prepreg layers 31
are formed by roller-pressing to obtain a stack 5 shown in FIG. 7,
followed by heat-pressing the stack 5 in a mold 6 to obtain the
case 8 (see FIGS. 8 and 9).
In detail, the mold 6 includes lower and upper mold units 61, 62.
The heat-pressing is conducted by disposing the stack 5 in a cavity
611 of the lower mold unit 61, disposing an airbag 7 above the
stack 5, and disposing the upper mold unit 62 above the lower mold
unit 61 so that the stack 5 and the airbag 7 are clamped between
the upper and lower mold units 62, 61. After the airbag 7 is
inflated and after heat is applied to the mold 6, the stack 5 is
formed into the case 8.
Preferably, a total weight of the outer prepreg layers 31 is less
than 40% of a weight of the case 8 of the electronic device. In the
preferred embodiment, the airbag 7 is made of nylon. However, the
airbag 7 may also be made of latex or silicone rubber.
The case 8 shown in FIG. 9 is formed according to the method of
this invention. An antenna (not shown) is disposed to correspond to
the antenna region 81 of the case 8 and has a size smaller than the
area of the antenna region 81. The fiber contained in the outer
prepreg layers 31 and the first fiber of the first prepreg sheets
411 permit permeation of an electromagnetic wave (a radio wave).
The second fiber of the second prepreg sheets 412 has relatively
high strength and rigidity. Therefore, the electromagnetic wave
(the radio wave) can be received by the antenna and can be emitted
from the antenna through the antenna region 81 of the case 8, and
the strength of the case 8 can be enhanced by the second fiber
contained in the second prepreg sheets 412 of the inner laminate
4.
It should be noted that the case 8 may include a monitor cover of a
notebook computer, and may be formed with a keyboard base of the
notebook computer based on a design of the notebook computer.
The case 8 of the electronic device and the method for forming the
same have the following advantages:
1. The antenna region 81 and the non-antenna region 82 of the case
8 of this invention are not required to be separately formed using
different molds unlike the method disclosed in the prior art, but
are integrally formed in the mold 6. Therefore, the case 8 formed
according to the method of this invention is cost-saving.
2. The electromagnetic wave (radio wave) will not be blocked by
fiber contained in the outer prepreg layers 31 and the first fiber
of the first prepreg sheets 411 in the antenna region 81 of the
case 8, and the strength of the case 8 can be enhanced by the
second fiber of the second prepreg layers 412 in the non-antenna
region 82.
3. Since the first prepreg sheets 411 (that are adapted to form the
antenna region 81) are respectively and seamlessly connected to the
second prepreg sheets 412 (that are adapted to form the non-antenna
region 82) between the outer prepreg layers 31, no bonding lines
are formed on the outer surface of the case 8. That is, the case 8
of this invention has a relatively smooth outer surface and the
unappealing appearance of the conventional case 1 attributed to the
bonding lines can be improved.
While the present invention has been described in connection with
what is considered the most practical and preferred embodiment, it
is understood that this invention is not limited to the disclosed
embodiment but is intended to cover various arrangements included
within the spirit and scope of the broadest interpretations and
equivalent arrangements.
* * * * *